Solar module array pre-assembly method

ABSTRACT

The present invention is directed to an apparatus for pre-assembly of an electrically connected array of solar panels for a solar canopy including a substantially planar base member for resting on a horizontal surface; a substantially planar support member; a track member disposed proximate a bottom portion of the support member attached to or integral with the support member or base member for vertically aligning side-by-side and vertically supporting a plurality of solar panels when a side edge portion of the solar panels rests on the track member; and at least two arm members, each having a free end and an attached end, the attached ends pivotally attached proximate to opposing ends of the base member or support member, the arm members being configured and adapted for removably attaching at least two solar panel support channels.

COPYRIGHT NOTICE AND AUTHORIZATION

This patent document contains material which is subject to copyrightprotection.

© Copyright 2010-2011. Chevron Energy Solutions Company, a division ofChevron U.S.A. Inc. All rights reserved.

With respect to this material which is subject to copyright protection.The owner, Chevron Energy Solutions Company has no objection to thefacsimile reproduction by any one of the patent disclosure, as itappears in the Patent and Trademark Office patent files or records ofany country, but otherwise reserves all rights whatsoever.

FIELD OF THE INVENTION

This invention relates an apparatus and method for pre-assembly ofcertain components of a solar canopy.

BACKGROUND OF THE INVENTION

Solar energy is a clean, renewal energy source. Photo-electro voltaiccell technology is increasing rapidly and makes installation of solarcollector panels housing the photo-electro voltaic cells more and moreeconomically feasible. Beyond the photo-electro voltaic cell technologyitself are the problems of placement and support of the solar collectorpanels. Large numbers of solar collector panels must be assembled inseries to achieve useful power production. In remote areas these may beplaced on the ground without interfering with land use. In moredeveloped areas, it is desirable to place the solar collector panelssuch that the land may also be used for other purposes, e.g., forparking lots, school/office hallways, playgrounds, or sports fields. Toachieve this requires an elevated structure to support the solarcollector panels.

In prior known systems, installation costs amount to around 25% of theoverall cost of a solar parking shade installation. These installationcost includes the cost to place modules on a rack, wire the modulestogether and to a combiner box, bolt the modules in place, and place thesupport structure on a parking shade structure. These costs often amountto almost the actual panel cost themselves due to the lack of ability toachieve assembly efficiency as well as the need in governmental marketsto use union labor.

An additional deficiency in known methods/systems for solar canopyinstallation is that the size of solar modules used is limited to thesize module a contractor can physically early. The installation processis also cumbersome and dangerous due to work on nonstandard sites and atan elevated height.

It is desirable to have a method and system which overcomes thedeficiencies of known systems. The instant invention provides such asolution.

SUMMARY OF THE INVENTION

The invention in one embodiment includes an apparatus for pre-assemblyof an electrically connected array of solar panels for a solar canopycomprising:

-   (a) a support member for aligning side-by-side a plurality of solar    panels with a bottom portion of the solar panels exposed; and-   (b) an arm member attached at one longitudinal end portion proximate    to the side portion of the support member and configured and adapted    for removably attaching at least two solar panel support channels.

The invention in another embodiment includes an apparatus forpre-assembly of an electrically connected array of solar panels for asolar canopy comprising:

-   (a) a base member horizontally disposed for supporting other    elements;-   (b) a support member having attached along one side portion of the    support member to the base member and an opposing side portion    disposed away from the base member for aligning side-by-side a    plurality of solar panels with a bottom portion of the solar panels    exposed; and-   (c) an arm member attached at one longitudinal end portion proximate    to the side portion of the support member attached to the base    member and configured and adapted for removably attaching at least    two solar panel support channels.

The invention in another embodiment includes an apparatus forpre-assembly of an electrically connected array of solar panels for asolar canopy comprising:

-   (a) a substantially planar base member for resting on a horizontal    surface,-   (b) a substantially planar support member for horizontally aligning    side-by-side and horizontally supporting a plurality of solar panels    when a photo-voltaic cell side of the solar panels rests against the    support member, wherein a bottom portion of the support member is    integral with the base member or fixed attached to the base member,    and the support member extends upward from the planar base member;-   (c) a track member disposed proximate a bottom portion of the    support member attached to or integral with the support member or    base member for vertically aligning side-by-side and vertically    supporting a plurality of solar panels when a side edge portion of    the solar panels rests on the track member; and-   (d) at least two arm members, each having a free end and an attached    end, the attached ends pivotally attached proximate to opposing ends    of the base member or support member and each arm members having a    longitudinal axis oriented substantially perpendicular to the    longitudinal axis of the base member and support member and    extending outward from the base member and support member, and    configured to pivot in a vertical plane from a position    substantially parallel to the ground upward to a position    substantially parallel to the plane of the support member, wherein    upon pivoting in one direction the free end moves closer towards the    support member and pivoting in the other direction the free end    moves away from the support member, the arm members being configured    and adapted for removably attaching at least two solar panel support    channels.

In another embodiment the invention includes a method for pre-assemblyof an electrically connected array of solar panels for a solar canopy,the method comprising:

The invention in another embodiment includes a method for pre-assemblyof an electrically connected array of solar panels for a solar canopy,the method comprising:

-   (a) aligning a plurality of solar panels side-by-side in an    electrically connected array of solar panels pre-assembly apparatus,    the pre-assembly apparatus comprising:-   a base member for resting on a horizontal surface;-   a support member for horizontally aligning side-by-side and    horizontally supporting a plurality of solar panels when a    photo-voltaic cell side of the solar panels rests against the    support member, wherein a bottom portion of the support member is    integral with the base member or fixed attached to the base member,    and the support member extends upward from the base member;-   a track member disposed proximate a bottom portion of the support    member attached to or integral with the support member or base    member for vertically aligning side-by-side and vertically    supporting a plurality of solar panels when a side edge portion of    the solar panels rests on the track member; and-   at least two arm members, each having a free end and an attached    end, the attached ends pivotally attached proximate to opposing ends    of the base member or support member and each arm members having a    longitudinal axis oriented substantially perpendicular to the    longitudinal axis of the base member and support member and    extending outward from the base member, and support member, and    configured to pivot in a vertical plane from a position    substantially parallel to the ground upward to a position    substantially parallel to parallel to the plane of the support    member, wherein upon pivoting in one direction the free end moves    closer towards the support member and pivoting in the other    direction the free end moves away from the support member, the arm    members being configured and adapted for removably attaching at    least two solar panel support channels;-   wherein a bottom portion of the plurality of solar panels is    supported by the track member and a front portion is supported by    the support member, facing inward towards the base member;-   (b) removably attaching at least two solar panel support channels to    the arm members of the solar panel array pre-assembly apparatus,    wherein the longitudinal axis of the solar panel support channels is    parallel to the longitudinal axis of the base member and positioned    to contact a bottom portion of all of the plurality of solar panels,    near opposite longitudinal ends of each of the plurality of solar    panels when the arm members are rotated about the longitudinal axis    of the base member where attached;-   (c) manipulating the position of the arm members of the electrically    connected array of solar panels pre-assembly apparatus relative to    position of the support member of the electrically connected array    of pre-assembly apparatus such that the solar panel support channels    contacts a bottom portion of the plurality of solar panels, near    opposite longitudinal ends of each of the plurality of solar panels,    thereby aligning the solar panel support channels for attachment to    bottom of the plurality of solar panels;-   (d) fixedly attaching a top portion of the solar panel support    channels to a bottom portion of each of the plurality of solar    panels; and-   (e) reversing the manipulation in step (c) of the position of the    arm members of the solar panel array pre-assembly apparatus relative    to position of the support member of the pre-assembly apparatus,    such that the plurality of solar panels and attached solar panel    support channels lay parallel with the ground surface and are ready    to be loaded on a truck for transportation to the job site.

These and other features and advantages of the present invention will bemade more apparent through a consideration of the following detaileddescription of preferred embodiments of the invention. In the course ofthis description, frequent reference will be made to the attacheddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of the present invention.

FIG. 2 is a top view of one embodiment of the present invention.

FIG. 3 is a side view in one embodiment of the present invention.

FIG. 4 is an opposite side view in one embodiment of the presentinvention.

FIG. 5 is a front view of one embodiment of the present invention.

FIG. 6 is a back view of one embodiment of the present invention.

FIG. 7 is a perspective view of one embodiment of the present inventionwith emphasis depicting the arm members for supporting Zee-channels orC-channels.

FIG. 8 is a perspective view of one embodiment of the present inventiondepicting one Zee-channel attached to the arm members.

FIG. 9 is a perspective view of one embodiment of the present inventiondepicting two Zee-channels attached to the arm members.

FIG. 10 is an alternate perspective view of one embodiment of thepresent invention depicting two Zee-channels attached to the armmembers.

FIG. 11 is a perspective view of one embodiment of the present inventiondepicting two Zee-channels attached to the arm members and one solarpanel resting in the track member.

FIG. 12 is a perspective view of one embodiment of the present inventiondepicting two Zee-channels attached to the arm members and one solarpanel resting in the opposite end of the track member.

FIG. 13 is a perspective view of one embodiment of the present inventiondepicting two Zee-channels attached to the arm members and a pluralityof solar panel resting in the track member.

FIG. 14 is a perspective view of one embodiment of the present inventiondepicting two Zee-channels attached to the arm members and a pluralityof solar panel resting in the track member, and the arm memberspartially folded/rotated upward towards the Zee-channels/support member.

FIG. 15 is a perspective view of one embodiment of the present inventiondepicting two Zee-channels attached to the arm members and a pluralityof solar panel resting in the track member, and the arm members fullyfolded/rotated upward towards the Zee-channels/support member, so as toplace the Zee-channels in position to be attached to the plurality ofsolar panels.

FIG. 16 is a perspective view of one embodiment of the present inventiondepicting two Zee-channels attached to the arm members and a pluralityof solar panel resting in the track member, and the arm members fullyfolded/rotated upward towards the two Zee-channels/support member, withthe Zee-channels attached to the plurality of solar panels, and a palletstructure in position to receive the two Zee-channels attached to theplurality of solar panels.

FIG. 17 is a perspective view of one embodiment of the present inventiondepicting the two Zee-channels attached to the plurality of solar panelsand supported by the pallet structure.

FIG. 18 is a perspective view of one embodiment of the present inventiondepicting the two Zee-channels attached to the plurality of solarpanels, released from the arm members, supported by the palletstructure, and in position to be picked up by a fork lift.

FIG. 19 is a perspective view of one embodiment of the present inventiondepicting the two Zee-channels attached to the plurality of solarpanels, released from the arm members, supported by the palletstructure, and being removed by a fork lift for loading on a truck totake to the job site.

FIG. 20 is a perspective view of one embodiment of the pallet structureof the present invention.

FIG. 21 is a top view of one embodiment of the pallet structure of thepresent invention.

FIG. 22 is a side view of one embodiment of the pallet structure of thepresent invention.

FIG. 23 is an end view of one embodiment of the pallet structure of thepresent invention.

FIG. 24 is a perspective view of one embodiment of multiple stackedpallet structures of the present invention with completed Zee-channelsattached to a plurality of solar panels loaded on each pallet structure.

FIG. 25 is a perspective view of one embodiment of the clamp structureof the present invention,

FIG. 26 is an alternate perspective view of one embodiment of the clampstructure of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Other embodiments of the present invention and its individual componentswill become readily apparent to those skilled in the art from theforegoing detailed description. As will be realized, the invention iscapable of other and different embodiments, and its several details arecapable of modifications in various obvious respects, all withoutdeparting from the spirit and the scope of the present invention.Accordingly, the drawings and detailed description are to be regarded asillustrative in nature and not as restrictive. It is therefore notintended that the invention be limited except as indicated by theappended claims.

As used in this specification and claims, the “solar panel supportchannels” comprise “Z”-shaped sheet metal, also referred to as“Zee-channels” or “7-channels”, “C”-shaped sheet metal, also referred toas “Cee-channels” or “c-channels”, or standard beams, bars, and othersuitable support members.

FIG. 1 is a perspective view of one embodiment of the present invention.The invention includes an apparatus 100 for pre-assembly of anelectrically connected array of solar panels for a solar canopy. Basemember 110 (having longitudinal and lateral side portions) is forresting on any solid stable horizontal surface capable of supporting theweight of the apparatus, workers, and solar panels to be assembled. Inone embodiment the base member 110 is substantially planar. Optionally,wheels 190 are attached at the bottom of base member 110 to allowrepositioning of the apparatus 100. In another embodiment (not shown)there is no base member 110 and instead support member 120 isself-supporting or supported, e.g., by attachment to a wall, floor orother fixture, or by placement of “post” legs at the bottom of thesupport member into “post” holes in the floor. In another embodiment thesupport member 120 is self supporting due to its shape, e.g., box-shapedor triangle shaped.

A support member 120 is fixedly or removably attached to base member 110and is for horizontally aligning side-by-side and horizontallysupporting a plurality of solar panels when a photo-voltaic cell side ofthe solar panels rests against the support member 120. In one embodimentthe support member 120 is substantially planar. A bottom portion ofsupport member 120 is integral with the base member or fixed attached tothe base member 110, and the support member 120 extends upward from thebase member 110. The support member 120 is inclined from verticalsufficiently for supporting the solar panels. In one embodiment thesupport member 120 is inclined from about 3 degrees to about 25 degreesfrom vertical. Optionally, support member 120 is comprised of a latticeframework. A solid form is another option, e.g. molded plastic or forgedmetal.

A track member 140 is disposed proximate a bottom portion of the supportmember 120 and is attached to or integral with the support member 120 orbase member 110 for vertically aligning side-by-side and verticallysupporting a plurality of solar panels when a side edge portion of thesolar panels rests on the track member 140. At least two arm members130, each having a free end and an attached end, the attached endspivotally attached proximate to opposing ends of the base member 110 orsupport member 120. In this embodiment one end of arm members 130 isattached to pivot bar 150 (also referred to as shaft member) and theopposing ends of pivot bar 150 are attached to brackets on opposing endsof base member 110. Each arm members 130 having a longitudinal axisoriented substantially perpendicular to the longitudinal axis of thebase member 110 and pivot bar 150 and extend outward from the basemember 110. The arm members 130 are configured to pivot in a verticalplane from a position substantially parallel to the ground upward to aposition substantially parallel to parallel to the plane of the supportmember 120.

Upon pivoting in one direction the free end of the arm members 130 movescloser towards the support member 120 and pivoting in the otherdirection the free end of the arm members 130 moves away from thesupport member 120. The arm members 130 are configured and adapted forremovably attaching at least two solar panel support channels (see FIGS.13 and 14). Also, the arm members 130 in one embodiment are configuredand adapted for removably attaching at least two solar panel supportchannels 810 (see FIG. 8) at multiple positions and spacing along thelongitudinal axis of arm members 130 so as to be suitable for use with aplurality of solar panel sizes. In one embodiment arms 130 are movableand may be adjusted along pivot bar 150 for different size solar panelarrays. Also, in another embodiment arm members 130 may be foldedtowards and against pivot bar 150 to allow for more easy transportationof the apparatus 100.

Optionally, one or more alignment beams 160 are attached to one of thearm members 130. Alignment beams 160 have a free end and a fixed endwhere the fixed end is movably attached perpendicularly to an arm member130 at one end of assembly 100 and extending away from other arm members130, i.e., in longitudinal alignment with the base member 110. Alignmentbeams 160 are configured and adapted for aligning and preventing lateralmovement of a solar panel support channels (see FIGS. 9 and 10), whereinthe alignment beam is adjustable along the length of the arm member tosuit various solar panel sizes. In another embodiment alignment beams160 may be folded towards and against arm members 130 to allow for moreeasy transportation of the apparatus 100.

Optionally, a tool rail 170 is attached via tool rail support arms 175to a top portion of support member 120 and is parallel to it. It isconfigured to receive a movable tool caddy 180 which can be slide alongthe tool rail 170 by a technician and has a hook, strap or other devicefor holding a tool such as an electric drill or riveter. The tool rail170 and tool caddy 180 reduces the lifting and moving work of thetechnician of heavy tools.

FIG. 2 is a top view of one embodiment of the present invention 200. Anadditional optional element more clearly shown in this figure is bracemembers 210 which attach to arm members 130 and pivot bar 150 where thetwo are joined.

FIG. 3 is a side view in one embodiment of the present invention 300.More clearly shown in this figure is the track in tool rail 170 in whichtool caddy 180 may slide. Also this side view more clearly shows one endof pivot bar 150 where it is rotatably attached to base member 110. Morethan one tool caddy 180 may be slid on tool rail 170, e.g., one for eachtechnician working on the assembly.

FIG. 4 is an opposite side view in one embodiment of the presentinvention 400.

FIG. 5 is a front view of one embodiment of the present invention 500.This view more clearly shows a plurality of optional wheels 190 attachedat the bottom of base member 110 to allow easy relocation of theapparatus 500.

FIG. 6 is a back view of one embodiment of the present invention 600,

FIG. 7 is a perspective view of one embodiment of the present invention700 with emphasis on depicting the arm members 130 for supportingZee-channels or C-channels. Also this figure more clearly shows a basemember protrusion 710 and “C” bracket 720 for securing each end of pivotbar 150. Also this figure depicts clamp member 730 attached to armmembers 130 for removably attaching, e.g., a Zee-channel (shown in FIG.8). For each Zee-channel used in the assembly of a solar module arraythere are at least two corresponding clamp members 730, i.e., one forattaching the Zee-channel to each of the preferably at least two armmembers 130. Any known clamping structure may be used, e.g., screw-downclamp, magnetic clamp, bar and clasp clamp, bar and lock clamp, to holdthe Zee-channel during assembly and to release the solar module array atthe Zee-channel after assembly is completed.

The clamp members 730 are preferably attached to respective arm members130 at equal distances from the pivot bar 150 so as to allow attachingthe Zee-channels parallel to the longitudinal access of the base member110. Where optional alignment beams 160 are attached to arm members 130,the clamp members are positioned so that when a Zee-channel is attachedvia a clamp member 730 one end of the Zee-channel rests along thealignment beam 160 and abuts its end portion, thus easily positioningthe Zee-channel for attachment to the bottom of solar panels (see FIGS.13 and 14).

FIG. 8 is a perspective view of one embodiment of the present invention800 depicting one Zee-channel 810 attached via clamp members 730 to thearm members 130. One end of the Zee-channel 810 rests along thealignment beam 160 and abuts its end portion.

FIG. 9 is a perspective view of one embodiment of the present invention900 depicting two Zee-channels 810 attached to the arm members 130, bothhaving one end resting along an alignment beam 160 and abutting an endportion of the alignment beam.

FIG. 10 is an alternate perspective view of one embodiment of thepresent invention 1000 depicting two Zee-channels 810 attached to thearm members 130, both having one end resting along an alignment beam 160and abutting an end portion of the alignment beam.

FIG. 11 is a perspective view of one embodiment of the present invention1100 depicting two Zee-channels 810 attached to the arm members and onesolar panel 1110 resting in the track member 140. The solar panel 1110has a bottom portion supported by resting in track member 140 and upperportion supported by leaning against support member 120.

FIG. 12 is a perspective view of one embodiment of the present invention1200 depicting two Zee-channels attached to the arm members 130 and onesolar panel 1110 resting in the opposite end of the track member 140from that shown in FIG. 11. This depicts one optional method of use ofthe apparatus 1200 where one end of the track member 140 and supportmember 120 is the “feed” end for feeding a plurality of solar panelsonto the apparatus. This mode would be convenient where the supply ofsolar panels 1110 is stacked on that side of the apparatus. Then eachsolar panel is slide to the opposite end of the track member 140 andsupport member 120 and this is repeated until a sufficient number ofsolar panels have been placed on the apparatus. Alternately, solarpanels 1110 could be feed from both ends of the track member 140 andsupport member 120, either alternately or simultaneously depending onavailable number of technicians and placement of solar panel stock.

FIG. 13 is a perspective view of one embodiment of the present invention1300 depicting two Zee-channels 810 attached to the arm members 130 anda plurality of solar panels 1110 resting in the track member 140 andagainst support member 120. The plurality of solar panels is nowpositioned for attachment of the Zee-channels 810.

FIG. 14 is a perspective view of one embodiment of the present invention1400 depicting two Zee-channels 810 attached to the arm members 130 anda plurality of solar panels 1110 resting in the track member 140 andagainst support member 120, and the arm members 130 partiallyfolded/rotated upward towards the support member 120.

FIG. 15 is a perspective view of one embodiment of the present invention1500 depicting two Zee-channels 810 attached to the arm members 130 anda plurality of solar panels 1110 resting in the track member 140 andagainst support member 120, and the arm members 130 folly folded/rotatedupward towards the support member 120 and bottom of solar panels 1110and in contact with the bottom of solar panels 1110 and thereforepositioned for attachment to the solar panels 1110 so as to place theZee-channels 810 in position to be attached to the plurality of solarpanels 1110. The positioning of the tool rail 170 is above the height ofarm members 130 when folly folded so as not to interfere with theirfolding.

FIG. 16 is a perspective view of one embodiment of the present invention1600 depicting two Zee-channels 810 attached to the arm members 130 anda plurality of solar panels 1110 resting in the track member 140, andthe arm members 130 fully folded/rotated upward towards the two supportmember 120, with the Zee-channels 810 now attached to the plurality ofsolar panels 1110, and a pallet structure 1610 in position to receivethe newly assembled solar module array 1710 (consisting of twoZee-channels 810 attached to the plurality of solar panels 1110).Optionally, the pallet structure 1610 is properly positioned to receivethe solar module array 1710 by abutting one side of pallet structure1610 against pivot bar 150.

FIG. 17 is a perspective view of one embodiment of the present invention1700 depicting the solar module array 1710 supported by the palletstructure. Once the solar module array 1710 is assembled by attachingthe Zee-channels 810 to the plurality, of solar panels 1110, the solarmodule array 1710 is lowered by reversing the rotation of the armmembers 130 until substantially horizontal, touching the floor or thesolar module array 1710 is resting on the pallet structure 1610. Raisingand lowering the arm structures is optionally achieved manually, or viaknown mechanical, pneumatic, or other mechanisms such as gears, winches,electric no motors. When the arm members 130 are being rotated up theyonly bear their own weight and the weight of the Zee channels 810. Whenthe arm members 130 are being lowered they bear the additional weight ofthe completed solar module array 1710 which is much heavier and so caremust be taken for safe lowering of this weight.

FIG. 18 is a perspective view of one embodiment of the present invention1800 depicting the solar module array 1710, released via clamp member730 from the arm members 130, supported by the pallet structure 1610,and in position to be picked up by a fork lift 1810.

FIG. 19 is a perspective view of one embodiment of the present invention1900 depicting the solar module array 171.0, released via clamp member730 from the arm members 130, supported by the pallet structure 1610,and being removed by a fork lift 1810 for loading on a truck to take tothe job site.

FIG. 20 is a perspective view of one embodiment of the palletstructure/assembly 2000 of the present invention. The pallet assembly2000 is configured and adapted for supporting the solar module array1710, which in one embodiment is electrically connected array of aplurality of solar panels 1110 fixedly attached to Zee-channels 810during storage and transport. The pallet assembly 2000 comprises a deck2010 (comprised of beam members 2060 and 2050 joined); a plurality offeet 2020 extending downward from the deck a sufficient depth to allowfor stacking of multiple pallet assemblies 2000 with one solar modulearray 1710 loaded on each pallet assembly 2000, i.e., at least thethickness of one solar module array 1710 plus any additional depthneeded for stacking; a plate (not shown) attached to an edge portion ofthe deck 2010, for aligning the pallet assembly 2000 with the apparatus100 (see e.g., FIG. 1) for building an electrically connected array of aplurality of solar panels, i.e., solar module array 1710; and at leastone alignment bracket 2040 for aligning and preventing lateral movementof at least two solar panel support channels 810, e.g., Zee Channels,attached to the bottom of the electrically connected array of aplurality of solar panels 1110. Other configurations of deck 2010 andfeet 2020 could include, e.g., a single integral molded plastic form, asolid deck or molded deck 2010 attached to feet 2020, a box-typestructure with a bottom recess to provide space for stacking, ordetachable legs that, e.g., are temporarily attached to a portion of asolar module array 1710.

FIG. 21 is a top view of one embodiment of the pallet assembly 2000 ofthe present invention, FIG. 22 is a side view of one embodiment of thepallet assembly 2000 of the present invention. FIG. 23 is an end view ofone embodiment of the pallet assembly of the present invention.

FIG. 24 is a perspective view of one embodiment of multiple stackedpallet assemblies 2000 of the present invention with completed solarmodule arrays 1710 loaded on each pallet structure. The upper portionand lower portions of feet 2020, shown at the 4 corners of the palletassemblies in this embodiment, are configured and adapted for stackingby any known methods, e.g., having a recess on the upper portion and amatching protrusion on the lower portion of each foot 2020 so the feetalign and stack securely when one pallet assembly is stacked on top ofanother pallet assembly. Alternative embodiments might include a lockinglatch member, snap latches, or other known connecting mechanisms. Sincewith stacking of pallet assemblies, the load is higher on the lowerpallet assemblies, the weight capacity of each pallet assembly must beweight on the bottom pallet assembly when stacked with the maximumcontemplated number of pallet assemblies. In addition, appropriatesafety margins should be used, e.g., to allow for additional dynamicload when transporting the stacked pallet assemblies. FIG. 25 is aperspective view of one embodiment of the clamp structure 730 of thepresent invention 2500, A base bracket 2525 is optionally used tofixedly or movably attach clamp structure 730 to arm member 130.Pressure pin member 2560 contacts an edge portion of Zee-channel 810 and“pins” the Zee-channel to arm member 130.

FIG. 26 is an enlarged alternate perspective view of one embodiment ofthe clamp structure 730 of the present invention. Clamp base 2535 isfixedly attached to base bracket 2525. A pneumatic, hydraulic, electric,or manually powered ram 2520 is actuated to cause piston 2530 to moveforward or backward in ram 2520. The movement of piston 2530 inrotatable coupling with hinge 2540 moves pin bracket 2550 open orclosed, i.e., up or down, thereby causing pressure pin member 2560 topin or release the Zee-channel 810. Various other clamp mechanisms andclamp actuating mechanisms may be used and are within the scope of theinvention.

Other embodiments of the present invention and its individual componentswill become readily apparent to those skilled in the art from theforegoing detailed description. As will be realized, the invention iscapable of other and different embodiments, and its several details arecapable of modifications in various obvious respects, all withoutdeparting from the spirit and the scope of the present invention.Accordingly, the drawings and detailed description are to be regarded asillustrative in nature and not as restrictive. It is therefore notintended that the invention be limited except as indicated by theappended claims.

What is claimed is:
 1. A method for pre-assembly of an electricallyconnected array of solar panels for a solar canopy, the methodcomprising: (a) aligning a plurality of solar panels side-by-side in anelectrically connected array of solar panels pre-assembly apparatus, thepre-assembly apparatus comprising: a base member for resting on ahorizontal surface; a support member for horizontally aligningside-by-side and horizontally supporting a plurality of solar panelswhen a photo-voltaic cell side of the solar panels rests against thesupport member, wherein a bottom portion of the support member isintegral with the base member or fixed attached to the base member, andthe support member extends upward from the base member; a track memberdisposed proximate a bottom portion of the support member attached to orintegral with the support member or base member for vertically aligningside-by-side and vertically supporting a plurality of solar panels whena side edge portion of the solar panels rests on the track member; andat least two arm members, each having a free end and an attached end,the attached ends pivotally attached proximate to opposing ends of thebase member or support member and each arm members having a longitudinalaxis oriented substantially perpendicular to the longitudinal axis ofthe base member and support member and extending outward from the basemember and support member, and configured to pivot in a vertical planefrom a position substantially parallel to the ground upward to aposition substantially parallel to the plane of the support member,wherein upon pivoting in one direction the free end moves closer towardsthe support member and pivoting in the other direction the free endmoves away from the support member, the arm members being configured andadapted for removably attaching at least two solar panel supportchannels; wherein a bottom portion of the plurality of solar panels issupported by the track member and a front portion is supported by thesupport member, facing inward towards the base member; (b) removablyattaching at least two solar panel support channels to the arm membersof the solar panel array pre-assembly apparatus, wherein thelongitudinal axis of the solar panel support channels is parallel to thelongitudinal axis of the base member and positioned to contact a bottomportion of all of the plurality of solar panels, near oppositelongitudinal ends of each of the plurality of solar panels when the armmembers are rotated about the longitudinal axis of the base member whereattached; (c) manipulating the position of the arm members of theelectrically connected array of solar panels pre-assembly apparatusrelative to position of the support member of the electrically connectedarray of pre-assembly apparatus such that the solar panel supportchannels contacts a bottom portion of all of the plurality of solarpanels, near opposite longitudinal ends of each of the plurality ofsolar panels, thereby aligning the solar panel support channels forattachment to bottom of the plurality of solar panels; (d) fixedlyattaching a top portion of the solar panel support channels to a bottomportion of each of the plurality of solar panels; and (e) reversing themanipulation in step (c) of the position of the arm members of the solarpanel array pre-assembly apparatus relative to position of the supportmember of the pre-assembly apparatus, such that the plurality of solarpanels and attached solar panel support channels lay parallel with theground surface and are ready to be loaded on a truck for transportationto the job site.
 2. The method of claim 1, further comprising a clampmember attached to each arm member for removably attaching a solar panelsupport channel.
 3. The method of claim 1, wherein the pre-assemblyapparatus further comprises a shaft member rotatably attached to a sideportion of the base member and perpendicularly to the attached ends ofeach arm member.
 4. The method of claim 1, wherein the pre-assemblyapparatus further comprises a motor attached to the shaft member forrotating the shaft member, thereby actuating pivoting of each armmember.
 5. The method of claim 1, wherein the support member of thepre-assembly apparatus has a height of at least half the longitudinalaxis of a solar panel it supports.
 6. The method of claim 1, wherein thesupport member of the pre-assembly apparatus comprises a latticeframework.
 7. The method of claim 1, wherein the arm members of thepre-assembly apparatus are further configured and adapted for removablyattaching at least two solar panel support channels at multiplepositions and spacing along the longitudinal axis of the arm members soas to be suitable for use with a plurality of solar panel sizes.
 8. Themethod of claim 1, wherein the pre-assembly apparatus further comprisesan alignment beam having a free end and a fixed end where the fixed endis attached perpendicularly to at least one of the arm members and isconfigured and adapted for aligning and preventing lateral movement of asolar panel support channels.
 9. The method of claim 1, wherein thesupport member of the pre-assembly apparatus is inclined from verticalsufficiently for supporting the solar panels.
 10. The method of claim 9,wherein the support member of the pre-assembly apparatus is inclinedfrom about 3 degrees to about 25 degrees from vertical.